162LRJS-C5240

Frequently Asked Questions

How to Install 161LRJS/162LRJS Loadbreak Elbow Connectors

This guide provides detailed instructions for the safe and proper installation of 161LRJS and 162LRJS Loadbreak Elbow Connectors on UD cable having jacketed concentric neutral wires and extruded insulation shielding.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Components

   Ensure all apparatus is de-energized before beginning installation or removal of parts (except test point caps/indicators). Do not touch or move energized products. Inspect all parts for damage, rating, and compatibility. Check package contents for completeness and proper fit. Thread the probe into the compression lug to check for resistance; replace damaged components if resistance is encountered. This product must be installed only by competent personnel trained in high voltage safety practices. Failure to follow instructions will result in serious injury or product damage.

2. Prepare Test Point Cap (162LRJS Only)

   If installing a 162LRJS connector and the test point cap is not pre-installed, lubricate the cap and test point with the supplied lubricant and install the cap.

3. Train Cable and Prepare Neutral Wires

   Train the cable to ensure sufficient slack for ease of operation. Mark the centerline of the bushing with tape. Pull extra cable 24-26 inches beyond the centerline. Remove the outer jacket 7 3/4 to 8 inches back from the centerline. Unwrap the neutral wires back past the bushing centerline. Cut the excess cable squarely at the centerline of the bushing. Connect the neutral wires to the tank ground with a jumper or grounding braid, providing extra length for hotstick operation.

4. Apply Mastic and Secure Neutral Wires

   Wrap one strip of mastic, stretching slightly, around the cable jacket. Bend all neutral wires straight back over the mastic and along the cable, pressing them firmly into the mastic. Wrap a second strip of mastic completely around the outer jacket, overlapping the imbedded neutral wires. Use a third strip of mastic if needed to build up the outer diameter in the area of the first mastic location. Cover all mastic with vinyl tape.

5. Prepare Cable Insulation and Conductor

   Remove the insulation shield and insulation from the cable end, cutting squarely and taking care not to nick the conductor. Wire brush bare aluminum conductors thoroughly and immediately install the compression lug. Rotate the lug to spread the inhibitor. Position the compression lug so its contact threaded hole aligns with the bushing bore. Refer to the crimp chart packaged with the compression lug for recommended crimp tool information. Start crimping at the crimp line mark, rotating 180 degrees for each successive crimp. Carefully wipe excessive inhibitor from the outside of the lug and cable. Remove the insulation shield as shown in the diagram. Bevel the insulation end a maximum of 1/8 inch. Thoroughly clean the insulation to remove all traces of conductive residue.

6. Lubricate and Slide Elbow Housing

   Lubricate the cable insulation and the inside of the elbow housing with the supplied lubricant. DO NOT SUBSTITUTE other lubricants, as they may be harmful. Keep the insulation clean of dirt and grime. Slide the elbow connector onto the cable using a back-and-forth twisting motion. Wipe off all excess lubricant.

7. Align Elbow and Install Probe

   Align the elbow with the compression lug's threaded hole. Thread the probe into the lug by hand, ensuring not to cross-thread. The probe should turn freely for approximately four turns before becoming snug. Tighten the probe with the supplied wrench until the wrench bends, indicating proper torque.

8. Connect Concentric Neutral Wires

   Pull the hood over the concentric neutral seal area on the cable by pulling the tabs and/or rolling the seal down. Insert one end of a separate copper wire (No. 14 AWG / 2.5mm) or equivalent through the grounding eye on the elbow, twisting tightly without damaging the eye. Twist all neutral wires together and connect them to ground using an appropriate connector, ensuring adequate slack in the wires for elbow operation.

9. Lubricate and Connect Elbow to Bushing

   Lubricate the receptacle portion of the elbow connector and the mating bushing with the supplied lubricant. IMPORTANT: Lubricate only if the transformer and elbow are known to be de-energized. Operate the connection using a fully insulated 'hotstick' type tool; DO NOT OPERATE BY HAND. Consult your company's safe work practices for the required tool length. Loadbreak connectors must be operated with a fully insulated 'hotstick' type live-line tool.

10. Perform Voltage Test (162LRJS Only)

    If using a 162LRJS connector, remove the test point cap with a hotstick, peeling it off at an angle. Use a suitable sensing device, specifically made for capacitive test points, to determine if the cable is energized; do not use conventional voltage measuring equipment. Follow the manufacturer's directions for the meter used. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point. WARNING: The test point is a capacitance device, not directly connected to the conductor. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious injury.

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